Let Additive Manufacturing Inspire You
3D printing Manufacturing cyclus OMC: Thema 1 - World Class productiemiddelen Peter Mercelis, PhD - 2013/09/19
1
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Overzicht Inleiding en voorstelling LW Basisprincipes 3D printing 3D printing: nieuwste hype of industriële revolutie? Introductie van nieuwe technologie in bestaande markten/producten Ontwikkeling van nieuwe markten / producten
2
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
LayerWise Incorporated in 2008 as spin-off from university of Leuven K.U.Leuven prof. Jean-Pierre Kruth
Focus on metal AM only Unique technological expertise in metal AM since 2001 Phd Jonas Van Vaerenbergh Phd Peter Mercelis 12 years experience with AM titanium
Developing AM technology and applications together with our customers 3
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
LayerWise markets
standard implants customized implants medical instruments
dental prostheses implant supported and cemented
aviation space
chemical pharma pressure & gas precision mechanics
ISO 9001 and ISO 13485 certified 4
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
semicon tooling food electronics imaging
Growth Additive Manufacturing 3D Printing
2001
2008
2009
100% prototyping 4 materials 90 x 90 x 90 mm worldwide first 3D printing of Titanium
2010
2011
2012
90% serial production 17 materials 280 x 280 x 440 mm largest metal 3D printing company in EU
technology development & production Benelux Germany USA ISO 9001 – ISO 13485 Quality Certified
5
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
2013
Technology basics Basic principle; 3D object is manufactured as a stack of 2D layers that are interconnected
6
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Technology basics
Directly from 3D CAD Layer-wise production 3D components by successive connection of thin 2D layers
7
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
8
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
9
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Hype or industrial revolution? 3D printing is not new!
industrial polymer-based technologies: °1986! Indirect metal technologies: late 90’s Direct metal technologies since: since 2000 Change in terminology: Rapid Prototyping Rapid Manufacturing / Rapid Tooling Additive Manufacturing 3D Printing
10
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Hype or industrial revolution? Media hype driven by consumer-applications of 3DP Home use 3D printers Available for low prices (< 1000 €) Low entry barrier
Online 3D printing services Shapeways, iMaterialise, etc. (source: De Bijenkorf)
11
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Consumer applications of 3DP Architectural models
Jewellery
12
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Consumer applications of 3DP Design
(source: Materialise NV)
(source: 3D systems 13
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Consumer applications of 3DP Fashion
(source: Materialise NV)
14
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Consumer applications of 3DP Online 3D printing websites give everyone access to 3DP technology
15
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Risks of the current 3DP hype Current media hype on 3DP created unrealistic expectations!
16
Organ printing possible in the near future … Everyone should have a 3D Printer @ home … Everything can be 3D printed … 3D printing is cheap …
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Risks of the current 3DP hype Importance of realistic expectations! 3DP is NOT a cheap manufacturing technology Traditional manufacturing will not disappear! 3DP often needs to be combined with traditional manufacturing methods
Traditional machining techniques generally have higher accuracy than 3DP Limited number of materials possible Size limitations limit the application field Printing of living tissue is still in its infancy! 17
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Hype or industrial revolution? The hyped technology has the potential to initiate an industrial revolution though Digital manufacturing without tooling Nearly unlimited shape complexity; Anatomical shapes Weight reduction Cooling/heating channels Transportation channels Eliminating assembly work
18
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Essence: the new technology should add value to the product/service compared with the traditional technology Added value: product/service definition Increased functionality = technical improvement Improved appearance = esthetic improvement Reduced drawbacks! 19
Ergonomics Safety Complexity Reliability Maintenance …
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Your technology should increase added value of your direct customer of the end customer only = more difficult of your direct customer and the end customer = easiest + synergetic
20
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Regulation; Existing products or markets are often regulated by government or by industry Examples: Medical implants standards (ISO / ASTM / FDA …) E.g. ASTM F2068 - 09 Standard Specification for Femoral Prostheses—Metallic Implants
Quality management systems (Medical / Aerospace …) E.g. ISO 13485
Technology standards; E.g. ASTM F1472 - 08e1 Standard Specification for Wrought Titanium-6Aluminum-4Vanadium Alloy for Surgical Implant Applications (UNS R56400)
Often no standards exist yet for a new technology in an existing market/ product category! 21
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product LW’s approach; Fulfill existing regulations that lie close to your new technology field and that your customers are familiar with LW uses ‘conventional’ material compositions LW’s titanium material performance fulfills the requirements of E.g. ASTM F1472 - 08e1 Standard Specification for Wrought Titanium-6Aluminum-4Vanadium Alloy for Surgical Implant Applications (UNS R56400)
Proactively follow and cooperate in standard development (ISO / ATSM)
22
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Innovative technology can be a trigger to convince innovators! But; this is a short term effect, in the end the it is the added value that counts to convince the early adopters and the majority
23
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Strategy; try to become a chameleon after convincing the innovators Most customers are not interested in technology, but simply want added value in their products or services Risk aversion of most (large) companies demands full compliance to their existing technologies, habits, existing standards and personal opinions … 24
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Illustration; dental prosthetics Traditional technology: Analog imprints Wax modeling Casting technique Labor intensive Inaccurate
Recent technologies: Digital prosthesis design Digital prosthesis manufacturing; CNC milling 3D printing / Additive Manufacturing 25
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Dental prostheses @ DentWise Digitalisation of the design and manufacturing process
Patented technology by LayerWise
Digital scanning at dentist practise is the logical next step
26
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Medical applications of AM Illustrations of dental applications of 3DP
27
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Added value; higher strength improved fixation, improved esthetics in final prosthesis, short lead time
Patented technology by LayerWise
28
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Added value for dental lab Reduced cost of prosthetic framework Easier finishing of dental prosthesis Removal of ‘dirty’ casting area from the lab!
Added value for end client (dentist / patient) 29
Faster troughput Higher strength of prosthesis Improved estheatics of prosthesis Reduced cost of prosthesis
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Use of internal cooling channels in tooling applications
30
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New technology for existing market/product Added value: Shorter cycle times Improved quality of injection molded products at these cycle times
However; LW is not successful in the tooling market Main reason; added value does not lie with our direct customer, the toolmaker! Added value lies with his customer, the injection molding company 31
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New product development Advantages; Few competitors More possibilities for IP protection
Disadvantages; Unknown market potential Market not yet aware of the application; missionary work even more difficult Higher investment costs
32
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New product development Importance of time to market for products with short life cycles Typical for medical markets: Scientific evidence is crucial Support of Key Opinion Leaders is important to convince majority
LW strategy; Partner with existing companies to develop new products in a shared risk setup Products that offer incremental improvements towards existing products are; Easier to develop Cheaper to develop Many times easier to sell
Radical new products only developed if IP protection is possible 33
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
New product development Illustration of new product development
Porous hip cup implant allowing full integration with human bone
Patient specific hip implant (courtesy of Mobelife NV) 34
www.layerwise.com © LayerWise NV, all rights reserved
23-Sep-13
Let Additive Manufacturing Inspire LayerWise NV You Kapeldreef 60 3001 Leuven Belgium www.layerwise.com – www.dentwise.eu Tel.: +32 16 29 84 20 Fax.: +32 16 29 83 19
35
www.layerwise.com © LayerWise NV, all rights reserved
Click to edit Master subtitle style 23-Sep-13
